Connector for insulation covered conductors



Dec. 30, 1969" A] D. D NQN 3,487,354

CONNECTOR FOR INSULATION COVERED CONDUCTORS Filed Jan. 26, 1968 2 Sheets-Sheet 1 INVENTO ALFRED D. DUN N zwgieg wdvt, MHz/- ATTORNEYS Dec. 30, 1

I CONNECTOR FOR INSULATION COVERED CONDUCTORS Filed Jan. 26, 1968 2 Sheets-s 2 ALFRED CAN BY /M ATTORNEYS United States Patent 3,487,354 CONNECTOR FOR INSULATION COVERED 'CONDUCTORS Alfred D. Duncan. 792 Cambridge, Elmhurst, Ill. 60126 Filed Jan. 26, 1968, Ser. No. 700,887 Int. Cl. H01r 11/20 US. Cl. 33998 8 Claims ABSTRACT OF THE DISCLOSURE Connector for electrically connecting insulation cov-- ered conductors including an insulating body for receiving insulation covered conductors and having a pressure element threadedly supported in the body, wherein the pressure element includes an annular electrically conductive cutting element that cuts the insulation and electrically connects the conductors when engaging same.

This invention relates in general to a connector for electrically connecting at least two insulation covered conductors together.

Heretofore, electrical connectors for connecting insulation covered conductors have been developed, but difficulty has been encountered in use of such connectors and in the eificiency of such connectors. Further, the cost of making heretofore known connectors has been relatively high and the connectors have involved complicated structures.

The connector of the present invention is very simple in structure and economical to manufacture and easy to use with the minimum amount of tools. The connector includes a body of insulating material having openings for receiving insulation covered conductors, and a pressure element that is capable of electrically connecting the insulation covered conductors. The pressure element may take several forms, but would always include an annular cutting element of electrically conductive material that would be carried on a support element threadedly mounted in the body, whereby movement of the pressure element within the body would cause cutting of the insulation on the insulation covered conductors and an electrical connection between the conductors by means of the annular cutting element. The invention is especially useful for connecting at least two insulation covered conductors together, although it may be readily applied to any number of conductors.

It is therefore an object of the present invention to provide a new and improved connector for electrically connecting insulation covered conductors.

Another object of this invention resides in the provision of a connector for electrically connecting insulation covered conductors that includes a body of insulating material capable of receiving at least a pair of insulation covered conductors, and a pressure element in the body having an annular electrically conductive insulation cutting element that is capable of cutting the insulation upon being moved into the body and ultimately providing an electrical connection between the conductors.

Other objects, features and advantages of the invention will be apparent from the following detailed disclosure, taken in conjunction with the accompanying sheets of drawings, wherein like reference numerals refer to like parts, in which:

FIG. 1 is a perspective view of a connector according to the present invention;

FIG. 2 is an exploded perspective view of the connector of FIG. 1;

FIG. 3 is a vertical sectional view taken through the connector of FIG. 1 and substantially along line 3-3 3,487,354 Patented Dec. 30, 1969 ICC of FIG. 1, and showing the pressure element out of engagement with the conductors;

FIG. 4 is a view similar to FIG. 3 but showing the pressure element in engaging position with the conductors;

FIG. 5 is a detailed sectional view taken substantially along line 5-5 of FIG. 4;

FIG. 6 is a perspective view of another form of connector according to the invention;

FIG. 7 is a perspective exploded view of the connector of FIG. 6;

FIG. 8 is a vertical sectional view of the connector of FIG. 6, illustrating the pressure element in position before engagement with the conductors and the insulating plug in readiness for insertion into the tool opening of the pressure element;

FIG. 9 is a view similar to FIG. 8 but illustrating the pressure element in engagement with the conductors and the insulating plug in position with the pressure element;

FIG. 10 is a detailed sectional view taken substantially along line 1010 of FIG. 9;

FIG. 11 is a perspective view of still another connector form of the invention;

FIG. 12 is a perspective exploded view of the connector in FIG. 11;

FIG. 13 is a vertical sectional view taken through the connector of FIG. 11 and substantially along line 1313 thereof and showing the pressure element out of engagement with the conductors;

FIG. 14 is a view similar to FIG. 13 but illustrating the pressure element in engagement with the conductors;

FIG. 15 is a detailed sectional view taken substantially along line 15-15 of FIG. 14;

FIG. 16 is a perspective view of another form of connector according to the invention;

FIG. 17 is an exploded perspective view of the connector of FIG. 16;

FIG. 18 is a vertical sectional view taken through the connector of FIG. 16 substantially along line 1818 thereof and illustrating the upper pressure element out of engagement with the conductors and the lower pressure element in engagement with the conductors; and

FIG. 19 is a top plan view of the connector in FIG. 16, showing some parts in dotted lines for purposes of clarity.

The connector of the present invention, as allustrated is principally useful for electrically connecting at least two insulation covered conductors, although it should be appreciated that any number of insulation covered conductors, although it should be appreciated that any number of insulation covered conductors may be connected together in accordance with the present invention. Further, the connector of the present invention may be such as to electrically connect a plurality of pairs of insulation covered connectors together, and may be employed in switches, plugs, terminal junctions and other devices wherever there is a need to electrically connect at least one insulation covered conductor to another conductor.

Moreover, the invention applies equally as well to solid core or stranded conductors.

Referring now to the drawings, and particularly to the embodiment of FIGS. 1-5, the connector shown here is generally designated by the numeral 20 and includes generally a body 21 of insulating material, and a pressure element 22 of insulating material and movably supported by the body.

This embodiment illustrates the electrical connection of a pair of insulation covered conductors 23. A hollow area or compartment 24 is defined within the body 21. Axially spaced conductor openings 25 are provided at opposite sides of the body which lead into the compartment 24 and permit the conductors to be brought in side-by-side within the body in the compartment 24.

While the body 21 is shown to be rectangular in configuration, it should be appreciated that it might take any desired geometrical shape. Similarly, the compartment 24 is cylindrical in shape but may take other forms, it only being necessary that room be provided to permit the side-by-side placement of a pair of conductors within a compartment. Also, while the conductor openings 25 are shown to be arranged on opposite sides of the body, it should be appreciated that they could be arranged on the same side or adjacent sides. It would even be possible to employ a single conductor opening that would be large enough to accept a pair of conductors.

The pressure element 22 is in the form of a setscrew wherein it includes a body having external threads thereon that mate with a threaded bore 26 provided in the connector body 21. A slot 27 is formed in the upper end of the pressure element to receive a bladed tool, such as a screwdriver, for enabling the movement of the pressure element within the threaded bore 26. Thus, rotation of the pressure element 22 in the threaded bore causes movement inwardly or outwardly. The threaded bore 26 is aligned and intercommunicates with the compartment 24 within the body so that the pressure element can be directed against the conductors arranged therein. An annular electrically conductive cutting element 28 is fixed to the lower end of the body of the pressure element 22 in any suitable fashion. For example, if the body of the pressure element is molded of plastic, the annular cutting element 28 may be arranged to be fixed to the body during the molding operation. While the lower conductor engaging edge of the annular cutting element 28 may be sharpened to provide the best possible cutting action, such is not absolutely necessary in view of the small thickness of the cutting element which according to manufacturing tolerances will enable the element to be sufiiciently sharp to effect good cutting action on the insulation. As seen in FIG. 3, the conductors 23 include a conductive element 29 that may be solid core or stranded which is enveloped by a covering of insulation 30. The pressure element 22 is shown in such a position in FIG. 3 that would permit insertion of the conductors 23 into the body, while FIG.4 shows the pressure element 22 drawn downwardly to cause cutting of the insulation 30 and engagement by the cutting element 28 of the conductors 29 in each of the insulation covered conductors 23 to thereby elfect an electrical connection between the conductors. The bottom wall of the compartment 24 acts as a back stop during the movement of the pressure element 22 into the body so that the conductors are held in place during the insulation cutting operation.

The embodiment of FIGS. 6-10 differs primarily in the pressure element which will be designated by the numeral 20A, and like numerals will be employed for other parts. Also, a stop means is illustrated that may be optionally employed where only stranded wire conductors are involved so as to preclude the possible complete cutting of the stranded wires.

-In this embodiment, the pressure element 22A includes a setscrew 31 having the annular insulation cutting element 32 integral at its lower end, and an Allen head socket 33 at its upper end. While the setscrew is shown to be of the Allen head type, it should be appreciated that it could be a slotted head setscrew or one having any other type of tool engaging area for effecting the necessary movement of the setscrew within the body 21 of the connector. The setscrew 31, other than having the annular cutting element thereon, may be of a conventional type and made of metal that is electrically conductive. The setscrew 31 would be rotatably driven to its seated position for causing electrical connection between the conductors within the body. Thereafter, a plug 34 could be suitably seated in the socket 33 of the setscrew in order to provide an exterior surface of the body that is entirely insulating. In this instance the plug 34 would be made of suitable insulating material, and would include a mating end portion 35 that would be receivable in the socket 33 of the setscrew 31. A suitable friction fit may be provided, although a threaded portion 36 may be optionally molded on the plug to aid in keeping the plug in place wherein the threaded portion would mate with the threaded bore 26. In the event that the conductors 23 were live when handling, a wrench of insulating material or made to insulate the hand of the user would be employed for driving the setscrew 31 into conductor engaging position as shown in FIG. 9. After the setscrew suitably engages the conductors to cause an electrical connection, the plug 34 may be inserted.

In order to preclude cutting of stranded wire, a suitable stop may be provided which would include an annular flange 37 formed on the setscrew 31 at a predetermined location which would coact with a detent stop 38 formed within the compartment 24 at a proper elevation. Thus, the setscrew 31 would be turned downwardly until the flange 37 strikes the stop 38 and such would preclude cutting of the stranded conductors arranged within the compartment.

The embodiment of FIGS. 1115 differentiates from the embodiment of FIGS. 15 only in that a modified pressure element is provided, and here will generally be designated by the numeral 2211. In this embodiment, the pressure element 22 includes upper and lower segments 39 and 40, wherein the upper segment is of insulating material and the lower segment is of electrical conductive material. Both upper and lower segments are threaded and this threading together provides the entire threading of the pressure element which coacts with the threaded bore 26 of the connector body. The upper section 39 is preferably molded right on the lower section 40 in any suitable manner to provide a one-piece element that insulates the conductors from the exterior of the body when the pressure element is in place as shown in FIG. 14. The annular cutting element 41 is formed on the lower section 40 in the same manner as in the setscrew 31 in the embodiment of FIGS. 6-10. In this embodiment, a screwdriver slot 42 is formed in the upper section 39 to receive a bladed screwdriver for causing movement of the pressure element into and out of the body. The operation and use of this connector is the same as the embodiment of FIGS. 15, wherein turning down of the pressure element 22b to the position as shown in FIG. 14 will cause electrical connection between the conductors in the compartment 24. The upper and lower segments 39 and 40 need not both be threaded, as threading of either one will perform satisfactorily. In some applications, only segment 40 should be threaded.

A further embodiment of the invention is shown in FIGS. 16-19 which differs from the other embodiments primarily in that it illustrates the invention capabilities of electrically connecting more than a single pair of instilation covered conductors.

The connector of this embodiment includes generally a body 43 of insulating material and pressure elements 44 and 45. The pressure elements 44 and 45 are of the type shown and specifically described in the embodiment of FIGS. 11-15, although it should be appreciated that they may be of any of the types illustrated and described. A pair of conductor receiving chambers or compartments 46 and 47 are defined within the body 43, each of which is respectively provided with conductor receiving openings 46a and 46b, and 47a and 47b. Insulation covered conductors 48 are received in the openings 46a and 46b, and electrically connected within the compartment 46 by the upper pressure element 44 when it is drawn downwardly against the conductors to cut the insulation and engage the conductors therein. Similarly, insulation covered conductors 49 are received in the openings 47a and 47b and electrically connected within the chamber 47 by the pressure element 45. For purposes of illustration, FIG. 18 shows the pressure element 44 out of engagement with respect to the conductors 48 and in a position to permit insertion of the conductors, while the pressure element 45 illustrates the operative position for electrically connecting the conductors 49. Thus, this embodiment illustrates the electrical connection of two pair of conductors by a connector according to the present invention. It should be further appreciated that any number of conductors may be electrically connected in any body of insulating material by a connector according to the present invention. It would even be possible to electrically connect more than the two conductors together.

It will be understood that modifications and variations may be efiected without departing from the scope of the novel concepts of the present invention.

The invention is hereby claimed as follows:

1. A connector for electrically connecting at least one pair of insulation-covered conductors comprising a body of insulating material having a conductor receiving chamber and openings extending into said chamber for receiving insulation-covered conductors, a threaded bore in said body opening into said chamber, a threaded pressure element in said bore having an annular electrically conducting cutting member thereon and arranged within said body and spaced from the insulation-covered conductors, said pressure element being of insulating material and including a tool engaging portion at its outer free end, whereby movement of said pressure element into said body causes said cutting member to cut into the insulation on said insulation-covered conductors and engage the conductors thereby effecting electrical connection therebetween.

2. A connector as defined in claim 1, wherein said pressure element includes an upper section of insulating material and a lower section of electrical conducting material to which is joined said annular cutting member.

3. A connector as defined in claim 1, and stop means on said body coacting with stop means on said pressure element to limit the movement of said pressure element into the body to preclude severing of the conductors.

4. A connector for electrically connecting at least two pairs of insulation-covered conductors by electrically connecting one of each insulation-covered conductors of one pair with one of each insulation-covered conductors of the other pair, said connector comprising a body of insulating material having first and second insulationcovered conductor receiving chambers, openings extending into one of said chambers for receiving one insulationcovered conductor of each pair, openings extending into the other of said chambers for receiving the other insulation-covered conductor of each pair, first and second threaded bores in said body, one opening into each of said first and second chambers, first and second threaded pressure elements, one for each of said bores, each pressure element being of insulating material and including a tool engaging portion at its outer free end and having an annular electrically conducting cutting member thereon and arranged within said body and respective bores and spaced from the insulation-covered conductors, whereby movement of said pressure elements into said body causes said cutting members to cut into the insulation on the respective insulation-covered conductors and engage the conductors thereby causing electrical connection therebetween.

5. A connector as defined in claim 4, wherein each said pressure element includes an upper section of insulating material and a lower section of electrical conducting material to which is joined said annular cutting member.

6. A connector as defined in claim 4, and stop means for each pressure element for limiting movement into said body to preclude severing of the conductors.

7. A connector for electrically connecting a pair of insulation-covered conductors comprising a body of insulating material having a conductor receiving chamber and a pair of axially spaced openings in said body extending into said chamber for receiving insulation-covered conductors, a threaded bore in said body opening into said chamber, a threaded pressure element of electrically conductive material in said bore having an annular insulation cutting member at the inner end and a tool engaging portion at its outer end, whereby movement of said pressure element into said body causes said cutting member to cut into the insulation on said insulationcovered conductors and engage the conductors thereby causing electrical connection therebetween, and insulation means over the outer end of the pressure element.

8. A connector for electrically connecting at least two pair of insulation-covered conductors by electrically connecting one of each insulation-covered conductors of one pair with one of each insulation-covered conductors of the other pair, said connector comprising a body of insulating material having first and second insulationcovered conductor receiving chambers, axially spaced openings extending into one of said chambers for receiving one inslation-covered conductor of each pair, axially spaced openings extending into the other of said chambers for receiving the other insulation-covered conductor of each pair, first and second threaded bores in said body, one opening into each of said first and second chambers, first and second threaded pressure elements of electrically conductive material, one for each of said bores, each pressure element having an annular insulation cutting member at the inner end and a tool engaging portion at its outer end, whereby movement of said pressure elements into said body causes said cutting members to cut into the insulation on the respective insulation-covered conductors and engage the conductors thereby causing electrical conduction therebetween, and insulation means over the outer ends of said pressure elements.

References Cited UNITED STATES PATENTS 1,064,920 6/ 1913 Lovejoy. 2,897,720 6/ 1961 Rivkin 339-99 3,350,677 10/1967 Daum 339149 FOREIGN PATENTS 471,769 7/1914 France. 1,215,113 11/1959 France.

MARVIN A. CHAMPION, Primary Examiner J. H. MCGLYNN, Assistant Examiner US. Cl. X.R. 

